Lightweight, boxed stringer useful in forming pallets for transporting products

ABSTRACT

A lightweight, boxed stringer useful in forming pallets for transporting products. The lightweight, boxed stringer is formed using a unique box container which encloses a lightweight core material. The core material may comprise a cardboard honeycomb or a plastic foam. The lightweight core material is enclosed by the side panels of the box container which also has elongated end tabs. These end tabs are folded over a sheet material to form a unitized pallet structure comprising two or more stringers in substantially parallel alignment and the sheet material placed on the stringers and enclosed by the end tabs.

RELATED APPLICATION

This application is a continuation-in-part of application Ser. No. 11/119,101, filed May 02, 2005.

FIELD OF THE INVENTION

This invention relates to a lightweight, boxed stringer which is useful in forming pallets used to transport products. The lightweight, boxed stringer is formed using a unique box container which encloses a lightweight core material which has sufficient compressive strength to form stringers which wrap around a sheet material upon which is placed the product(s) to be transported.

BACKGROUND

In shipping products, it is standard practice to use pallets made of wood or other materials (e.g. gypsum board strips or plastic foams) as carriers for the products to be shipped or transported. When these pallets are used for shipping products, the products are usually stacked on the pallets, and the pallets carrying the products are moved to and from storage to transporting vehicles using forklift trucks. The receiving facility, retail store or factory, has to deal with disposing of the pallets. In some cases, the receiving facility collects and stores the pallets for return to the manufacturer.

U.S. Pat. No. 5,174,448 discloses a cardboard container for stacking glass sheets which is carried on a reusable wood pallet. This illustrates the standard method for shipping product carried by a reusable wood pallet.

U.S. Pat. No. 5,141,109 discloses using strips of scrap gypsum board to form pedestals to support a shipping container above the ground or floor whereby a forklift truck can be used to move the container. The patent also shows shipping bands, straps, ribbons, tapes, cords or wires which surround the container and the pedestals.

U.S. Pat. No. 3,855,756 discloses sub-unitized containers carried on a wood pallet with a heat-shrunk enveloping material holding the containers as an integral container on the pallet.

It is an object of this invention to provide a lightweight, boxed stringer useful in forming pallets which comprises a box container which encloses a lightweight core material, with said box container having end tabs which wrap around a sheet material upon which product(s) to be transported are placed.

It is another object of this invention to provide a lightweight, boxed stringer useful in forming pallets which comprises a box container which encloses a lightweight core material, with said box container having end tabs of sufficient length to wrap around a sheet material and to overlap each other or to interconnect with a linking piece whereby the end tabs can be attached.

It is a further object of this invention to provide two or more lightweight, boxed stringers in substantially parallel alignment, said stringers comprising a box container which encloses a lightweight core material, with said box containers having end tabs wrapped around a sheet material and overlapping and attached whereby both stringers are securely attached to the sheet material so as to form pedestals enabling a forklift truck to slide its blades under the sheet material.

The objects and advantages of this invention will be readily understood from a consideration of the drawings and the following detailed description of the preferred embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

In the description of the preferred embodiments of the invention presented below, reference is made to the accompanying drawings in which:

FIG. 1 is a top plan view of a box container used to form the stringer(s) of this invention showing creases in the side panels and end tabs in the flat container with slots in the end tabs to attach the end tabs to each other.

FIG. 2 is a top plan view of a box container used to form the stringers of this invention showing a lightweight core material in dashed lines placed on the central panel of the box container.

FIG. 3 is a top plan view of a box container used to form the stringers of this invention showing the side panels of the box folded over the lightweight core material.

FIG. 4 is a perspective view showing two stringers of this invention in substantially parallel alignment showing a sheet material in dashed lines enclosed by the end tabs of one stringer with the sheet material placed on the side panel of the box folded over the lightweight core material of the other stringer.

FIG. 5 is a perspective view showing two stringers of this invention in substantially parallel alignment showing a sheet material in dashed lines enclosed by the end tabs of both stringers and also shown in dashed lines is a bucket or drum-like product placed on an end tab and on the sheet material.

FIG. 6 is a perspective view showing two stringers of this invention in substantially parallel alignment showing a sheet material in dashed lines placed on the side panels of the boxes folded over the lightweight core material of the stringers with several boxed strip products in dashed lines overlying the sheet material and aligned perpendicular to the stringers.

FIG. 7 is a perspective view showing two stringers of this invention in substantially parallel alignment showing a sheet material in dashed lines placed on the side panels of the boxes folded over the lightweight core material of the stringers with several boxed strip products in dashed lines overlying the sheet material and extending beyond the sheet material and the stringers, with the end tabs of the stringers folded over the boxed strip products with the slots in the end tabs of the stringers interlocked whereby the boxed strip products are held in place against the sheet material.

FIG. 8 is a top plan view of a box container having shortened side panels and end tabs used to form the stringers of this invention showing creases in the side panels and end tabs in the flat container and a linking piece with slots in the end tabs and the linking piece to interconnect the shortened end tabs with the linking piece.

FIG. 9 is a perspective view showing two stringers of this invention in substantially parallel alignment showing a sheet material in dashed lines enclosed by the shortened end tabs of one stringer interconnected with a linking piece and the shortened side panels of the other stringer are folded upward to form a tray-like box containing the lightweight core material with the linking piece shown prior to engaging the shortened end tabs.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

This invention relates to a lightweight,.boxed stringer which is useful in forming pallets used to transport products. The lightweight boxed stringer is formed using a unique box container which encloses a lightweight core material which has excellent compressive strength. Two or more stringers are aligned substantially in parallel, and the end tabs of the box container wrap around a sheet material and the end tabs are securely fastened together whereby the stringers are attached to the sheet material so as to form a pallet. Products to be transported, including strips, sheets, buckets and drums, can be placed on the sheet material attached to the stringers for transport to a manufacturing facility or a retail store. Multiple stringers may be required for warehouse storage of elongated products.

The boxes used to form the lightweight, boxed stringers of this invention can be made from a variety of cardboard or plastic materials. The cardboard can be compressed cellulosic fibers, laminated heavy paper or cardboard sheets, or corrugated cardboard having flat sheet surfaces with a corrugated (i.e. furrowed or ridged) sheet between the flat surfaces. The boxes can also be made from plastic materials which are resistant to water and weather. In particular, corrugated plastic materials, such as used in realty “for sale” signs, can be used to make the stringers.

The lightweight core material, which must have excellent compressive strength, can be selected from cardboard honeycomb material, a plastic foam or other comparable lightweight materials. The side panels of the cardboard box container are folded over the lightweight core material, and when folded over the core material, it is preferred that the side panels overlap each other. However, it is within the scope of this invention that the side panels do not overlap each other. It is possible that there is a space between the side panels when they are folded over or they may abut instead of overlapping. In addition, the side panels can be shortened to such an extent that they do not overlap the lightweight core material, but instead form an open, tray-like box which contains the lightweight core material.

After the side panels are folded over the lightweight core material to form a stringer, two or more stringers are aligned substantially in parallel, and a sheet material is placed on top of the side panels folded over the core material. The sheet material can be selected from plywood, particle board, gypsum wallboard, plastic sheets and other materials such as honeycomb board and cardboard sheets having sufficient strength to support the product(s) being transported.

After placing the sheet material on the side panels of the box folded over the core material, the end tabs of the boxes are folded over the sheet material so as to enclose the sheet material and attach the stringers to the sheet material. The end tabs of the boxes are of sufficient length that they overlap when folded over the sheet material. The overlapping end tabs are fastened together by interlocking the tabs with slots made in each tab. In addition, the overlapping tabs can be fastened together with an adhesive or a mechanical fastener such as heavy staples.

It is within the scope of this invention for the end tabs to be shortened and not overlapping. In this alternative, a separate linking piece can be used to interconnect with the shortened end tabs. The linking piece can be fastened to the shortened end tabs by means of slots which interlock with slots in the end tabs, or the linking piece can be fastened to the shortened end tabs with an adhesive or a mechanical fastener such as heavy staples. The linking piece is generally made from the same material as the container box, e.g. cardboard or plastic materials.

As described above, the stringers which are attached to the sheet material separate the sheet material from the floor or ground. It is standard practice to use forklift trucks to transport pallets containing products. Since the stringers separate the sheet material from the floor or ground, the forklift truck can slide its blades under the sheet material on which the product to be transported is placed.

The advantages provided by the lightweight, boxed stringers of this invention are cost savings, with the cost of the box containers and core material being substantially less than the cost of wood pallets. There are also substantial savings in freight costs by eliminating the weight of wood pallets. Furthermore, the receiving factory or retail store does not have to deal with storage and/or disposal of the wood pallets. The box containers can be disposed of with other paper-like materials which are normally sold to a paper recycling company. Plastic box containers and core material, whether cardboard honeycomb or plastic foam, can also be recycled. An additional benefit would be conserving the timber natural resource needed to make wood pallets.

For a description of a preferred embodiment of this invention, reference is made to the drawings which illustrate a lightweight, boxed stringer in accordance with the invention.

FIG. 1 illustrates a box container (10) in its unfolded form. The container (10) comprises a central rectangular panel (11) on which will be placed a lightweight core material. Contiguous to the central rectangular panel (11) and of substantially equal length thereto are two side panels (12) and (13) both of which are creased, with the creases (14) and (15) extending the length of the side panels and located at a distance from the side edges of the central rectangular panel (11) to accommodate the thickness of the lightweight core material. The lightweight core material (see FIGS. 2 and 3) is enclosed by folding the side panels (12) and (13) over the lightweight core material. The width of the side panels (12) and (13) from the creases (14) and (15) to the outer edges (16) and (17) of the side panels (12) and (13) respectively is preferably substantially the width of the central rectangular panel (11). However, it is preferred that the width of the side panels (12) and (13) be sufficient that the side panels overlap when they are folded over the lightweight core material. It is also within the scope of the invention that the side panels (12) and (13) do not overlap when folded over the lightweight core material. As previously noted, it is possible that there is a space between the side panels when they are folded over the lightweight core material, or they may abut instead of overlapping. In addition, the side panels can be shortened to such an extent that they do not overlap the lightweight core material. In this latter case, the box container forms an open, tray-like box which contains the lightweight core material.

In addition to side panels (12) and (13), the box container (10) has end tabs (18) and (19) contiguous to the two ends of the central rectangular panel (11). Both end tabs (18) and (19) are creased, with the creases (20 and 21) and (22 and 23) being located at a distance from the end edges of the central rectangular panel (11) whereby creases (20) and (22) accommodate the height of the lightweight core material (not shown), and creases (21) and (23) accommodate the thickness of the sheet material (not shown) to be placed on the side panels. As shown in FIG. 1, the end tabs (18) and (19) have slots (24) and (25) which interlock when the end tabs (18) and (19) are folded over the sheet material.

Referring now to FIG. 2, the same box container (10) as shown in FIG. 1 is illustrated in FIG. 2 using the same numerals as in FIG. 1. Also shown in FIG. 2 is a lightweight core material (26) in dashed lines placed on the central panel (11) of the box container (10). The lightweight core material (26) can be selected from cardboard honeycomb material, a plastic foam or other comparable lightweight materials having sufficient compressive strength to support the products to be transported on the pallet. It is generally preferred to use a cardboard honeycomb material because of lower cost and ease of disposal. In addition, the side panels (12) and (13) are shown as slightly folded about the creases (14) and (15) respectively. Also as shown in FIG. 2, the lightweight core material (26) overlays the entire central rectangular panel (11) of the box container (10).

FIG. 3 illustrates a lightweight, boxed stringer (27) of this invention with the side panels (12) and (13) folded over the lightweight core material (26). As shown in this Figure, the side panels (12) and (13) completely overlap when folded over the lightweight core material (26). It is preferred that the side panels overlap when folded over the core material, but this is not essential to the invention.

FIG. 4 illustrates two stringers of this invention (27) and (27′) in substantially parallel alignment. Each stringer comprises a box container (10) with the side panels (12) and (13) folded over and enclosing the lightweight core material (26). A sheet material (28) is shown in dashed lines overlaying side panels (12), and stringer (27′) is shown as enclosed by end tabs (18) and (19). Stringer (27′) has the end tabs (18) and (19) interlocked at the end tab slots (29) whereby the stringer (27′) is firmly attached to the sheet material (28). As previously noted, the sheet material (28) may be selected from the group consisting essentially of plywood, particle board, gypsum wallboard and plastic sheets.

As shown in FIG. 4, the end tabs (18) and (19) have slots (24) and (25) which when folded over the sheet material (28) can be interlocked as shown at (29) which unitizes the stringer (27′) and fastens and secures the stringer (27′) to the sheet material (28). Instead of interlocking the end tabs by means of slots made in each end tab, the overlapping end tabs can be fastened together with an adhesive, or a mechanical fastener such as heavy staples or a Velcro fastener. The unitized stringers (27) and (27′) secured to the sheet material (28) form a pallet base upon which product to be transported can be placed.

FIG. 5 shows two stringers of this invention (27) and (27′) in substantially parallel alignment with a sheet material (28) in dashed lines enclosed by the end tabs (18) and (19) of both stringers. Also shown in dashed lines is a bucket or drum-like product placed on the end tab (18) and on the sheet material (28). This illustrates that the lightweight, boxed stringers of this invention can be used to form pallets for transporting buckets, pails, drum-like products and other products which are not in strip or sheet form.

FIG. 6 shows two stringers of this invention (27) and (27′) in substantially parallel alignment with a sheet material (28) shown in dashed lines placed on the side panels (12) of the boxes folded over the lightweight core material (26) of the stringers (27) and (27′). Several boxed strip products (29) shown in dashed lines are placed on the sheet material (28) and aligned perpendicular to the stringers (27) and (27′). In this arrangement, the end tabs (18) and (19) of both stringers can be folded over both the sheet material (28) and the boxed strip products (29) to form a unitized structure, or the sheet material (28) can be omitted, for the boxed strip products (29) can serve the same function (i.e. provide a platform) as the sheet material (28).

FIG. 7 shows two stringers of this invention (27) and (27′) in substantially parallel alignment with a sheet material (28) shown in dashed lines placed on the side panels of the boxes folded over the lightweight core material of the stringers (27) and (27′). A layer of boxed strip products (29) shown in dashed lines is placed on the sheet material (28) and aligned perpendicular to the stringers (27) and (27′). The end tabs (18) and (19) of both stringers are folded over both the sheet material (28) and the layer of boxed strip products (29) to form a unitized structure. Another layer of boxed strip products (30) is placed on top of the layer (29) and perpendicular thereto. The layer (30) is not enclosed by the end tabs, but is carried by the unitized structure comprising the two stringers (27) and (27′), the sheet material (28) and the layer of boxed strip products (29). In this particular illustration, the layer of boxed strip products (29) extends beyond the two stringers (27) and (27′). As also shown in FIG. 6, the sheet material (28) can be omitted, for the boxed strip products (29) can serve the same function as the sheet material (28).

As shown in FIG. 7, it is preferred to place each additional layer of boxed strip product at right angles to the layer beneath it for greater stability. The products placed on the unitized stringers and sheet material can be further stabilized by applying stretch wrap, heat shrink wrap, or bands to prevent slippage or spillage during shipping or transporting.

FIG. 8 illustrates a box container (10) having shortened side panels (31) and (32) and shortened end tabs (33) and (34). Creases (35) and (36) enable the shortened side panels (31) and (32) to be folded upwardly and at right angles to the central rectangular panel (11). In this species, the box container (10) will be in the form of a tray-like box into which the lightweight core material (not shown) is placed.

In addition to having shortened side panels (31) and (32), the species illustrated in FIG. 8 also has shortened end tabs (33) and (34). As a result, this box container (10) requires a separate linking piece (37) to interconnect with the shortened end tabs (33) and (34). The linking piece (37) has end slots (38) and (39) which engage the slots (24) and (25) in the shortened end tabs (33) and (34). As shown in FIG. 8, the end slots (38) and (39) appear along the same edge of the linking piece (37), but these slots can be on opposite edges if desired.

FIG. 9 shows two stringers of this invention (40) and (40′) in substantially parallel alignment. Each stringer comprises a box container (10) having shortened side panels (31) and (32) and shortened end tabs (33) and (34). The box container (10) is in the form of a tray-like box which contains the lightweight core material (26). A sheet material (28) is shown in dashed lines overlaying the box container (10) which contains the lightweight core material (26). Since the end tabs (33) and (34) are shortened and do not overlap, it is necessary to use the linking piece (37) to interconnect with the shortened end tabs (33) and (34). The end slots (38) and (39) in the linking piece (37) engage the slots (24) and (25) in the shortened end tabs (33) and (34). The end tabs (33) and (34) of the stringer (40′) are shown folded over the sheet material (28) and interconnected with the linking piece (37). The stringer (40′) is fastened and secured to the sheet material (28) and forms a unitized structure therewith.

This invention has been described in detail, with particular reference to preferred embodiments, but it should be appreciated that variations and modifications can be effected within the scope of the invention. 

1. A lightweight, boxed stringer useful in forming a pallet comprising a box container which in its unfolded, flattened form comprises a central rectangular panel; two side panels contiguous to the central rectangular panel, both of said side panels having creases extending the length of the side panels and being located at a distance from the side edges of the central rectangular panel substantially equal to the height of a lightweight core material which is placed on the central rectangular panel; said side panels being folded over on top of and enclosing said lightweight core material; two end tabs contiguous to the two ends of the central rectangular panel, both of said end tabs being creased enabling the end tabs to be folded over to enclose the two ends of the lightweight core material and to enclose a sheet material which is to be placed on top of the side panels folded over the lightweight core material, with the length of the end tabs being sufficient that the end tabs overlap each other when folded over the lightweight core material and the sheet material whereby the end tabs can be attached to one another.
 2. The lightweight, boxed stringer of claim 1 in which the lightweight core material is selected from the group consisting of cardboard honeycomb material and a plastic foam.
 3. The lightweight, boxed stringer of claim 1 in which the lightweight core material is cardboard honeycomb material.
 4. The lightweight, boxed stringer of claim 1 in which the end tabs are attached to one another by means selected from the group consisting of interlocking slots in the end tabs, adhesives and mechanical fasteners.
 5. A pallet for transporting products comprising at least two lightweight, boxed stringers in substantially parallel alignment, said lightweight, boxed stringers comprising a box container which in its unfolded, flattened form comprises a central rectangular panel; two side panels contiguous to the central rectangular panel, both of said side panels having creases extending the length of the side panels and being located at a distance from the side edges of the central rectangular panel substantially equal to the height of a lightweight core material which is placed on the central rectangular panel; said side panels being folded over on top of and enclosing said lightweight core material; two end tabs contiguous to the two ends of the central rectangular panel, both of said end tabs being creased whereby the end tabs are folded over to enclose the two ends of the lightweight core material and to enclose a sheet material which is placed on top of the side panels folded over the lightweight core material, and means firmly attaching the end tabs to one another, whereby the lightweight, boxed stringers are firmly attached to the sheet material so as to form a unitized pallet.
 6. The pallet of claim 5 in which the sheet material is selected from the group consisting of plywood, particle board, gypsum wallboard and plastic sheets.
 7. The pallet of claim 5 in which the lightweight core material is selected from the group consisting of cardboard honeycomb material and a plastic foam.
 8. The pallet of claim 6 in which the lightweight core material is a cardboard honeycomb material.
 9. The pallet of claim 5 in which the means firmly attaching the end tabs to one another comprises a linking piece which is attached to the end tabs, which are shortened, by means selected from the group consisting of interlocking slots, adhesives and mechanical fasteners.
 10. The pallet of claim 5 in which a sheet material is placed on top of the side panels folded over the lightweight core material, with the length of the end tabs being sufficient to enclose both the sheet material and a layer of boxed strip products which are placed on top of the sheet material, whereby the lightweight, boxed stringers are firmly attached to the sheet material and the layer of boxed strip products so as to form a unitized pallet.
 11. The pallet of claim 5 in which the length of the end tabs is sufficient that the end tabs overlap each other and are firmly attached to one another by means selected from the group consisting of interlocking slots, adhesives and mechanical fasteners.
 12. The pallet of claim 11 in which the end tabs are attached to one another by interlocking slots in the end tabs.
 13. A pallet for transporting products comprising at least two lightweight, boxed stringers in substantially parallel alignment, said lightweight, boxed stringers comprising a box container which in its unfolded, flattened form comprises a central rectangular panel; two shortened side panels contiguous to the central rectangular panel, both of said side panels having creases extending the length of the side panels and being adjacent to the side edges of the central rectangular panel with the height of the side panels when folded at right angles to the central panel being substantially equal to the height of a lightweight core material which is placed on the central rectangular panel; two end tabs contiguous to the two ends of the central rectangular panel, both of said end tabs being creased whereby the end tabs are folded over to enclose the two ends of the lightweight core material and to enclose a sheet material which is placed on top of the lightweight core material in the tray-like boxed container, and means firmly attaching the end tabs to one another, whereby the lightweight, boxed stringers are firmly attached to the sheet material so as to form a unitized pallet.
 14. The pallet of claim 13 in which the sheet material is selected from the group consisting of plywood, particle board, gypsum wallboard and plastic sheets.
 15. The pallet of claim 12 in which the lightweight core material is selected from the group consisting of cardboard honeycomb material and a plastic foam.
 16. The pallet of claim 12 in which the lightweight core material is a cardboard honeycomb material.
 17. The pallet of claim 12 in which the end tabs are attached to one another by means selected from the group consisting of interlocking slots in the end tabs, adhesives and mechanical fasteners.
 18. The pallet of claim 12 in which the means firmly attaching the end tabs to one another comprises a linking piece which is attached to the end tabs, which are shortened, by means selected from the group consisting of interlocking slots, adhesives and mechanical fasteners.
 19. The pallet of claim 12 in which the length of the end tabs is sufficient that the end tabs overlap each other and are firmly attached to one another by means selected from the group consisting of interlocking slots, adhesives and mechanical fasteners.
 20. The pallet of claim 18 in which the end tabs are attached to one another by interlocking slots in the end tabs. 